Method of manufacturing a ceramic article

- Eastman Kodak Company

The present invention is a method of preparing a ceramic article which includes compacting a particulate alloy of a primary oxide and a secondary oxide to form a blank. The primary oxide is zirconium oxide and the secondary oxide is selected from MgO, CaO, Y.sub.2 O.sub.3, Sc.sub.2 O.sub.3,CeO.sub.2 and rare earth oxides and combinations thereof. The blank is sintered in contact with a smectite containing sol.

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Claims

1. A method of preparing a ceramic article having a core with a tetragonal crystal structure and an outer layer with a monoclinic crystal structure comprising:

compacting a particulate alloy of a primary oxide and a secondary oxide to form a blank, said primary oxide comprising zirconium oxide, said secondary oxide selected from the group consisting of MgO, CaO, Y.sub.2 O.sub.3, Sc.sub.2 O.sub.3, CeO.sub.2, rare earth oxides and combinations thereof; and
sintering said blank in contact with a smectite containing sol.

2. The method of claim 1 wherein said sintering is at a temperature of from 1300.degree. C. to 1600.degree. C.

3. The method of claim 1 wherein said sintering is at a temperature of 1500.degree. C.

4. The method of claim 1 wherein said sol has a concentration of from 0.1 to 30 percent smectite.

5. The method of claim 1 wherein the smectite comprises a layered hydrous magnesium silicate.

6. The method of claim 1 wherein said particulate alloy has a concentration of said secondary oxide form 2 to 20 mole percent relative to the total of said secondary and primary oxides.

7. The method of claim 1 wherein said particulate alloy has a concentration of of said secondary oxide of form 2 to 5 mole percent relative to the total of said secondary and primary oxides.

8. The method of claim 1 wherein said blank has a density of from 40 to 65 percent of the density of the ceramic article.

9. A method of sintering a blank to provide a ceramic article having a core with a tetragonal crystal structure and an outer layer with a monoclinic crystal structure said blank compacted from a particulate alloy of a primary oxide and a secondary oxide to form a blank, said primary oxide comprising zirconium oxide, said secondary oxide selected from the group consisting of MgO, CaO, Y.sub.2 O.sub.3, Sc.sub.2 O.sub.3, CeO.sub.2, rare earth oxides and combinations thereof, said method comprising

sintering said blank in contact with a smectite containing sol.

10. The method of claim 9 wherein said sintering is at a temperature of from 1300.degree. C. to 1600.degree. C.

11. The method of claim 9 wherein said sintering is at a temperature of 1500.degree. C.

12. The method of claim 9 wherein said sol has a concentration of from 0.1 to 20 percent smectite.

13. The method of claim 9 wherein said particulate alloy has a concentration of said secondary oxide form 2 to 20 mole percent relative to the total of said secondary and primary oxides.

14. The method of claim 9 wherein said particulate alloy has a concentration of said secondary oxide form 2 to 5 mole percent relative to the total of said secondary and primary oxides.

15. The method of claim 9 wherein said blank has a density of from 40 to 65 percent of the density of the ceramic article.

Referenced Cited
U.S. Patent Documents
5336282 August 9, 1994 Ghosh et al.
5358913 October 25, 1994 Chatterjee et al.
5677072 October 14, 1997 Chatterjee et al.
Patent History
Patent number: 5804131
Type: Grant
Filed: Oct 7, 1997
Date of Patent: Sep 8, 1998
Assignee: Eastman Kodak Company (Rochester, NY)
Inventors: Debasis Majumdar (Rochester, NY), Dilip K. Chatterjee (Rochester, NY), Syamal K. Ghosh (Rochester, NY)
Primary Examiner: Christopher A. Fiorilla
Attorney: Carl F. Ruoff
Application Number: 8/946,046